A growth area in the food service industry is pulp-based thermoformed articles, such as plates, bowls, trays and clamshells. In order to effectively hold a variety of foods for both point-of-service and takeout uses, molded pulp articles must have the ability to resist both water and oil penetration. The standard test of molded pulp’s holdout properties requires exposing the material to hot water and hot or warm oil, with a target holdout of 30 to 60 minutes or more.
Traditionally, molded fiber manufacturers have used perfluoroalkyl substance (PFAS)-based products for oil resistance and alkyl ketene dimer (AKD)-based products for water holdout.There has been growing regulatory pressure to stop using PFAS, prompting the industry to look for suitable alternatives.
Replacing PFAS surface treatments in molded pulp food containers has proven to be challenging, mainly because these articles are three-dimensional and don’t lend themselves easily to traditional coating processes. A solution that replaces PFAS must:
- Have compatibility with and run cleanly on existing equipment.
- Achieve acceptable performance with real foods under realistic usage conditions.
- Demonstrate cost-effectiveness.
- Meet regulatory requirements for the applicable markets.
- Be compostable per Biodegradable Products Institute (BPI) standards.
Solenis has developed a new series of products designed to replace the use of PFAS in the production of molded pulp food containers while meeting specific end-use performance requirements. In fact, these solutions have reliably achieved excellent water holdout, as well as oil holdout, up to 45°C for one hour. Some systems have been successful in achieving oil holdout for one hour up to 60°C.
Customized Options
The Solenis TopScreen™ portfolio of sustainable barrier coatings and treatments delivers superior oil and water resistance in both paper and molded pulp products. Now Solenis brings the TopScreen™ technology innovation to molded fiber food service applications — in the form of ContourSM PFAS-free oil and grease resistant technology.
- The ContourSM technology platform is a unique combination of TopScreen™ products designed to deliver oil and grease resistance, replacing PFAS in molded fiber food service articles such as bowls and plates.
- ContourSM technology can be customized depending on the type of pulp and molding conditions to meet the desired performance in low- to mid-temperature end-use applications. Development of a next-generation version is underway to meet the performance needs for higher temperature end use.
- Best of all, ContourSM is an easily implemented replacement for PFAS, which requires minimal equipment costs and process management changes.
Environmentally Friendly Innovation
Using Solenis’ latest innovationin molded fiber technology, papermakers can now manufacture molded fiber packaging that is better for the environment yet still satisfies the needs of consumers. Our molded pulp packaging is biodegradable and meets the ASTM D6400 standard and specifications required to be compostable.
Versatile Solution
Solenis technologies allow for food-grade molded pulp packaging that remains cost competitive with similar products. Our solutions can be used to make a variety of thermoformed articles, including:
- Plates
- Bowls
- Trays
- Clamshells
More Information
Our PFAS-replacement technology may not be right for every producer or for every application. To discover whether Solenis’ solutions for molded fiber packaging can address your needs, ask a Solenis expert today.
